VOLKSWAGEN PASSAT 2006 (04) PDF Document

The VOLKSWAGEN PASSAT 2006 uses two main types of maintenance-free batteries:

1. Battery with magic eye: This is a maintenance-free wet battery with liquid electrolyte. It is equipped with a “magic eye” that provides information about the electrolyte level and the charge state of the battery through a colored display.

2. Absorbent Glass Mat (AGM) battery: This is a maintenance-free battery where the electrolyte is contained within a microscopic glass mat. It is sealed, fitted with valves, and does not have a magic eye. AGM batteries are identified by the abbreviation “AGM” on the battery itself. When replacing an AGM battery, it must always be replaced with another AGM battery.

When handling the battery on your VOLKSWAGEN PASSAT 2006, observe the following safety regulations:

Dangers and Precautions:

• Only trained personnel should work on batteries.

• Battery acid is highly corrosive. Keep a suitable neutralizing solution (like soap solution) available for acid burns.

• Leaking electrolyte can cause skin burns and corrosion on the vehicle.

• The gas formed during charging is explosive. Do not handle the battery incorrectly to avoid an explosion.

• Batteries with a colorless or light yellow magic eye must be renewed and not checked, charged, or jump-started due to explosion risk.

• Prohibit sparks, grinding, welding, cutting, naked lights, and smoking near batteries. Avoid electrostatic charging by touching the vehicle body before the battery.

• Only work on batteries in well-ventilated rooms.

Safety Markings on the Battery:

1. Fires, sparks, naked flames, and smoking are prohibited. Avoid short circuits; never lay a tool on a battery.

2. Always wear eye protection.

3. Keep children away from acid and batteries.

4. Dispose of old batteries as hazardous waste through a suitable collection center.

5. Never dispose of old batteries in household waste.

6. Be aware of the explosion danger from the highly explosive gas produced during charging.

7. Always follow instructions on the battery and in the owner’s manual.

8. Battery acid is caustic; wear eye protection and gloves. Do not tilt the battery, as acid can leak from vents.

To prevent damage to the battery clamps and terminals on your VOLKSWAGEN PASSAT 2006, observe the following points:

• The battery clamps should only be fitted by hand and without using force.

• Battery terminals should not be coated with grease.

• The battery clamps should be fitted so that the battery terminal is either flush with the clamp or protruding from it.

• Once the battery clamps have been tightened to the specified torque, the threaded connections should not be tightened any further.

A visual inspection of your VOLKSWAGEN PASSAT 2006 battery is essential before performing any extensive tests. This check establishes the following:

• Housing Damage: Check if the battery housing is damaged. If it is, electrolyte can leak out, causing serious damage to the vehicle. Treat any components affected by leaked acid immediately with an acid neutralizer or soap solution.

• Terminal Condition: Check whether the battery terminals (wire connections) are damaged. Damaged terminals prevent a guaranteed good contact with the battery clamps. When connecting the clamps, tighten them to the specified torque. If they are not correctly seated and tightened, the wiring may burn, causing electrical system malfunctions.

• Secure Mounting: Check that the battery is securely seated. If necessary, tighten the securing bolt to the specified torque. Vibrations from an unsecured battery can shorten its life, damage the cell plates, and potentially damage the battery housing, creating a risk of explosion.

The magic eye on your VOLKSWAGEN PASSAT 2006 battery provides information about the electrolyte level and charge state. Before checking, lightly tap the magic eye with a screwdriver handle to dissipate any air bubbles that could distort the colour. Note that the display applies to only one cell, so a full battery test is more accurate.

There are two types of magic eye displays:

“3-Colour” Magic Eye:

• Green: Battery is charged sufficiently.

• Black: Battery is partly discharged (charge state < 65 %) or completely discharged.

• Colourless or light yellow: Battery must be renewed. Do not check, charge, or jump-start the vehicle as there is a danger of explosion.

“2-Colour” Magic Eye:

• Black: Electrolyte level is OK.

• Colourless or light yellow: Electrolyte level is too low. The battery must be renewed. Do not check, charge, or jump-start the vehicle.

After performing a battery load test with the VAS 5097 A tester, you will receive a printout. The test results can be assessed as follows:

The results from the VAS 6161 battery tester for your VOLKSWAGEN PASSAT 2006 require different actions depending on the test type (Guarantee/Service or Maintenance).

Evaluating Battery Test Results for Guarantee and Service Tests

Evaluating Battery Test Results for Maintenance Test

The no-load voltage test is used to assess the battery’s condition on stock and stored vehicles during prescribed maintenance. It determines if the battery requires recharging.

Test Conditions:

• The battery must not have been charged or discharged within the last 2 days.

Procedure:

1. Use a hand multimeter (e.g., V.A.G 1526 B) to check the battery no-load voltage.

2. Assess the results based on the following table:

A no-load voltage of 11.60 V corresponds to a 0% charge, meaning the battery is discharged and has no capacity.

To charge the battery on your VOLKSWAGEN PASSAT 2006 with the VAS 5095 A charger, follow these steps:

1. Ensure the battery has a temperature of at least 10 °C.

2. Switch off the ignition and all electrical consumers.

3. On the base of the charger, set the battery type switch to 2.4 V/C (volts/battery cell).

4. Connect the red terminal clamp (+) of the charger to the positive terminal on the battery.

5. Connect the black terminal clamp (-) of the charger to the negative terminal on the battery. For vehicles with a start/stop function and battery monitor control unit (J367), the black clamp must be connected to body earth to avoid system malfunction.

6. Switch on the battery charger.

7. Monitor the charging current indicators. When the yellow LEDs (indicators 2 and 3) are lit, the battery is charging. When only the yellow LED for indicator 3 is lit, the battery is approximately 90% charged.

8. When the green LED (indicator 4) lights up, the charger has switched to “maintaining charge,” and the battery is fully charged.

9. Switch off the charging unit.

10. Remove the charger terminals from the battery terminals.

The cruise control system (CCS) on your VOLKSWAGEN PASSAT 2006 is controlled by the engine control unit. To activate or deactivate it, you need to use a vehicle diagnostic tester.

1. Connect the vehicle diagnostic tester to your vehicle.

2. Select “Guided fault finding” mode on the tester.

3. Using the “GoTo” button, select “Functions/component” and navigate through the following menu options in sequence:

• Drive

• Engine code

• 01 – On Board Diagnostic capable systems

• Engine management/diesel direct injection and glow plug system

• Functions

• Activating and deactivating cruise control system (CCS)

Follow the on-screen instructions provided by the diagnostic tester to complete the process.

Different types of hose couplings are used for the washer systems on your VOLKSWAGEN PASSAT 2006. Here is how to handle them:

Windscreen and Rear Window Washer System

• Type 1 (No securing device):

– To loosen: Pull the two coupling sections apart.

– To secure: Push the two sections together until you hear and feel them engage.

• Type 2 (Rotating lock ring):

– To loosen: Rotate the lock ring (item -1-) through 90° and pull off the hose connection.

– To secure: Push on the hose connection and rotate the lock ring back until it engages.

• Type 3 (Pull-up lock ring):

– To loosen: Pull up the lock ring (item -1-) by approx. 1 mm and pull off the hose connection.

– To secure: Attach the hose connection and press in the clip (item -1-) until it engages.

Headlight Washer System

• Push-lock ring type:

– To loosen: Push the lock ring (item -1-) in the direction of the arrow and pull off the hose connection.

– To secure: Push and hold the lock ring and push on the hose connection. Check that the securing clip has correctly engaged by trying to pull it off without the clip.

Repairs to the washer system hoses depend on whether the pipe is smooth or corrugated.

Repairing Smooth Pipe (5×1 mm or 6×1 mm)

1. Cut the damaged section out of the smooth pipe at right angles.

2. Select the appropriate EPDM hose and cable ties from the electronic parts catalogue (ETKA).

3. Cut the EPDM hose so that the ends of the smooth pipe can each be pushed about 10 mm into it.

4. Secure the repair joints with cable ties.

Repairing Corrugated Pipe

You will need a hot air blower for this repair. Repair points must not be subjected to pulling or bending forces.

1. Cut the damaged section out of the corrugated pipe at right angles.

2. Select suitable end pieces and the correct sized shrink-fit piping from the parts catalogue.

3. Heat one end of the corrugated pipe and push a connector into it.

4. Heat the other end of the corrugated pipe and push the other connector into it.

5. Cut a piece of heat-shrink hose so that the ends of the corrugated pipe are each covered by about 20 mm of the hose.

6. Push the heat-shrink hose over the corrugated pipe, join the connectors, and secure the repair joints by shrinking the hose with the hot air blower.

Working on the gas discharge (xenon) headlights of your VOLKSWAGEN PASSAT 2006 is dangerous due to high voltage, pressure, and temperature. Always observe the following safety rules:

High Voltage:

• Before working on any parts marked with yellow high-voltage symbols, you must disconnect the battery earth strap.

• After disconnecting the battery, switch the dipped beam on and off again to eliminate any residual voltage.

• Control units for light systems and their components conduct lethally high voltage. Never operate the control unit without a bulb fitted.

• Ensure the ignition is off, all electrical consumers are off, and the ignition key is removed.

Pressure, Temperature, Radiation/Arcs:

• The bulbs must only be operated in the headlight housing.

• H7 and gas discharge bulbs are under pressure and can explode if changed improperly, causing injury. Always wear protective goggles and gloves.

• The glass of the bulbs can get very hot, creating a danger of burns.

• Avoid looking directly into the beam. The UV rays are about 2.5 times greater than normal halogen bulbs, and the glare can impair vision.

Repair and Disposal:

• Do not touch the bulb glass with bare fingers; use clean cloth gloves to prevent oil from impairing brightness.

• Gas discharge bulbs must be disposed of as hazardous waste, as they contain metallic mercury (Hg) and traces of thallium. Never destroy them.

The procedure for removing and installing an illuminated cigarette lighter socket requires a special tool.

Special Tools Required:

• Puller -T 40148-

Removing the Socket:

1. Remove the cigarette lighter or dummy lighter from the socket if present.

2. Push the puller -T 40148- into the socket so that its locking lugs engage in the recesses inside.

3. Pull the grip on the puller to release the locking lugs of the retaining sleeve.

4. Pull the socket out of the retaining sleeve using the puller. Be careful not to stretch the wiring.

5. Pull off the socket connector.

6. To release the puller from the socket, press the spindle on the puller and turn the puller briefly to the left.

Removing the Illumination Bulb (L28):

1. With the socket removed, press the retaining lugs on the sleeve and remove the sleeve together with the bulb carrier.

2. Unclip the bulb carrier from the retaining sleeve.

3. Separate the bulb carrier into its two parts (A and B) and open part B.

4. Remove the light bulb.

Installing:

Installation is carried out in the reverse order of removal. After reassembly, carefully press the socket’s retaining springs together and check that the cigarette lighter remains in its removal position after a heating phase to ensure it does not eject from the vehicle interior.

When performing repairs on the vehicle electrical system of your VOLKSWAGEN PASSAT 2006, follow these guidelines:

• Always observe the latest notes in the respective workshop manual.

• Always disconnect the battery earth strap before working on the electrical system to ensure a safe working environment.

• Before starting a repair, identify and rectify the cause of the damage (e.g., sharp edges, corrosion, defective components).

• Soldering is not permitted for repairs to vehicle wiring.

• Use the appropriate wiring harness repair set (e.g., VAS 1978 B). Wiring harness repairs should be marked with yellow adhesive tape to indicate a previous repair.

• Crimp connectors may never be repaired. After crimping, they must be shrink-fitted with a hot air blower to prevent moisture ingress.

• Observe supplementary information for repairs to airbag systems, fibre optic cables, CAN bus lines, and aerial cables.

• Perform a function test after every repair. It may be necessary to interrogate and erase the fault memory.

• If possible, do not loosen any earth wires from the body to avoid the risk of corrosion.

• Screened wires must not be repaired; they must be replaced completely if damaged.

• For heat-resistant wiring (found mainly in the engine compartment, identifiable by its matt and softer insulation), only use heat-resistant wiring for repairs.

Repairing an open circuit involves using crimp connectors. The procedure depends on whether you are using one repair position or bridging a gap with a new piece of wire.

Repair with One Repair Position (Single Crimp Connector):

1. Place the wire to be repaired to one side.

2. Cut out the damaged piece of wiring using wire strippers (e.g., VAS 1978/3).

3. Strip 6-7 mm of insulation from both wire ends.

4. Push a single crimp connector onto both stripped wire ends and crimp it using the correct recess on the crimping pliers. The insulation must not be crimped.

5. After crimping, shrink-fit the connector using a hot air blower. Heat the connector from the middle outwards until it is sealed and adhesive escapes from the ends.

Repair with Two Repair Positions (Interlinked Wire):

This method is used if the wire ends are too short after cutting out the damage.

1. Place a new yellow repair wire next to the damaged harness and cut it to the required length.

2. Cut the damaged section out of the vehicle’s own wire.

3. Strip the ends of the vehicle’s wiring and the new repair wire by 6-7 mm.

4. Push a crimp connector onto one end of the vehicle’s wire and one end of the repair wire, and crimp them together.

5. Repeat the procedure on the other end of the repair wire.

6. Shrink-fit both crimp connectors using a hot air blower.

When multiple wires are repaired, ensure the crimp connectors are offset slightly to prevent the wiring harness from becoming too thick.

Releasing contacts from housings on your VOLKSWAGEN PASSAT 2006 requires using the correct release tools and understanding the locking mechanisms.

1. Disengage the Secondary Locking Element:

• The secondary lock is a housing catch that secures all wires in the connector. It is usually a different color from the rest of the housing.

• This mechanism must be opened or removed before individual contacts can be released.

• Examples of disengagement include removing a “toothed element,” opening a “flap,” or detaching a “slide.” A small screwdriver can be used as an aid.

2. Disengage the Primary Locking Element:

• The primary lock fixes an individual crimp contact within the housing.

• To release a contact, insert the appropriate release tool into the release port of the contact housing.

• Grab the wire and push the contact lightly *into* the housing. This lifts the locking tabs of the contact off the housing edge.

• At the same time, push the release tool further into the housing and pull the released contact out from the back.

• Once the contact is removed, the release tool can be pulled out of the housing.

Never use force to pull contacts out of the housings. Always use the correct release tool for the specific connector type (e.g., round, flat, Faston, GT 150/280).

The VAS 6410 cleaning set ensures optimal contact for high-current connections like starting and charging circuits. Do not use penetrating fluid, contact spray, or grease, as this can affect torque values.

Repairing Ring Terminals:

1. Disconnect the battery.

2. Loosen the cap nut and remove the ring terminal from the threaded connection.

3. Check the ring terminal for corrosion and dirt.

4. Select a suitable adapter and sanding pad (grey for light dirt, red for heavy dirt).

5. Insert the adapter into the ring terminal and grind off corrosion with circular movements. Be careful not to abrade the tin coating excessively, as exposing the copper can cause a galvanic cell and faulty repair.

6. Check the terminal and regrind if necessary. Use a deburrer to remove any punching burr.

7. Tighten the ring terminal to the specified torque.

8. Apply a suitable anti-corrosion treatment.

9. Reconnect the battery.

Repairing Threaded Connections:

1. Follow steps 1-3 from the ring terminal repair.

2. Select a suitable adapter and sanding pad for the threaded connection.

3. Set the adapter on the threaded connection and grind off corrosion with circular movements, checking progress visually.

4. Tighten the connection to the specified torque.

5. Follow steps 8-9 from the ring terminal repair.

Do not repair Lambda probe wires, as this can result in malfunctions. The procedure depends on whether you have a 4-pin (LSF) or 6-pin (LSU) probe.

Renewing LSF Lambda Probe (4-pin):

1. Remove the defective Lambda probe.

2. Place the old probe and the new uniform probe next to each other so the sensor housings are at the same height.

3. Tie back any excess length in the new probe’s wire (approx. 50-250 mm) to match the length of the defective probe and secure with cable ties.

4. Check that the connector housing of the new probe is compatible with the onboard supply side connector. If not (on older vehicles), replace the onboard supply system connector with the new one provided.

5. Install the new Lambda probe in the vehicle.

Renewing LSU Lambda Probe (6-pin):

1. Remove the old Lambda probe.

2. Place both probes next to each other with the sensor housings aligned.

3. Tie back any excess length in the new probe’s wire to match the old one and secure with cable ties.

4. Install the new Lambda probe in the vehicle.

For both types, if necessary, replace any attachment parts, cable ties, or marking rings from the old probe onto the new uniform probe to ensure a correct fit.